Method of making wheel covers



Jan. 2, 1962 G. A. LYON METHOD OF MAKING WHEEL COVERS Filed July 22, 1955 3 Sheets-Sheet. 1

22.27. tar 4mm Azamr 1m Jan. 2, 1962 G. A. LYON METHOD OF MAKING WHEEL COVERS 3 Sheets-Sheet 2 Filed July 22, 1955 Jan. 2, 1962 e A. LYON METHOD OF MAKING WHEEL COVERS 3 Sheets-Sheet 3 Filed July 22, 1955 llzazziur 6750/96! ALMRrLm/v United Stes Patent I 3,915,294 METHQD 6F h iAKlNG WHEEL QQVERS George Albert Lyon, Detroit, Mich assignor to Lyon Incorporated, Detroit, Micln, a corporation of Delaware Filed July 22, 1955, Ser. No. 523,674 3 Claimsa (Cl. 113-116) The present invention relates to improvements in wheel structures and more particularly concerns the method of making an ornamental and protective covering for the outer sides of vehicle wheels.

A modern trend in automobile wheels is toward smaller size and greater Width to accommodate larger sizes of tire for ride improvement. At the same time, in order to emphasize such wheel style and in order to obtain ornamental effects that impart a fairly massive appearance in the smaller diameter wheel, there has been a demand for wheel covers afiording a deeply drawn efiect in the ornamental configurations thereof. This has created problems not only in the manufacture of wheel covers from sheet metal but also in the mounting of the covers to attain the desired results.

An object of the invention is to provide an improved method of making wheel covers from sheet material whereby marginal retaining flange means is provided with an especially elongated efflciently reinforced retaining flange and seating structure.

According to the general features of the present invention, there is provided a method of making wheel covers, shaping a sheet metal blank into a circular member body with a return-bent outer generally radially projecting marginal formation and a retaining flange extending axially therefrom in concealed relation spaced radially inwardly from the edge of said marginal formation, supporting said marginal formation against axial displacement, and while thus supporting said marginal formation bending said axially extending flange intermediate its length into a generally radially inwardly extending offsetting reinforcing and seating shoulder but maintaining the flange on opposite axial sides of the shoulder'in the axial orientation but with the free end portion of the flange offset radially inwardly relative to the axial portion of the flange between said shoulder and said marginal formation.

Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of a pre erred embodiment thereof taken in conjunction with the accompanying drawings, in which:

FIGURE 1 is an outer side elevational view of a wheel structure embodying features of the invention;

FIGURE 2 is an enlarged fragmentary radial sectional view taken substantially on the line Il-ll of FIG. 1;

FIGURE 3 is a developed side elevational view of the cover of FIG. 2;

FIGURE 4 is a fragmentary radial sectional view through a blank that has been partially formed to pr vide the radimly outer portion of the cover;

FIGURE 5 is a view similar to FIG. 4 but showing the blank in a further stage of formation thereof;

FIGURES 6 and 7 are similar views showing further steps in the formation of the cover blank;

FIGURE 8 is a diametrical sectional view, more or less schematic, showing novel apparatus for completing the cover member; and

FIGURE 9 is a fragmentary sectional elevational view similar to FIG. 8 but showing the apparatus in a difierent operative relationship. I

A wheel cover made according to the present invention is adapted to be applied to the outer side of a vehicle wheel (FIGS. 1 and 2) including a disk spider wheel body 10 having a central bolt-on flange 11 surrounded by an outer annular deeply inset portion 12 at the radially outer side of which is an axially outwardly extending annular attachment flange 13 suitably secured to a base flange 14 of a drop center, multi-flange tire rim. At the axially outer side of the base flange i4 is a generally axially outwardly facing side flange 15 from the radially outer side of which extends obliquely radially outwardly and axially outwardly an intermediate flange 17 merging with a radially outwardly and then axially outwardly turned terminal flange 18. The flanges of the tire rim are constructed and arranged to support a pneumatic tire 19 which may be of the tubeless type but may be a tire and tube assembly if desired.

Herein the wheel cover is of the high crown type including an inner circular cover member 20 and an outer circular cover member 21. These cover members are constructed and related to provide a high crown and a high marginal structure with a deeply dished intermediate groove juncture. To this end, the radially inner crown cover member 2% includes a central high crown portion 22 having a generally axially inwardly extending side wall 23 of a diameter to extend down into the substantial groove within the annularly dished portion 12 of the wheel body while the crown 22 extends axially outwardly to a substantial extent in overlying relation to the wheel body and more particularly the bolt-on flange portion 11 thereof.

At its axially inner extremity, the side wall 23 has a generally radially outwardly and axially outwardly turned head 24 within which is lock seamed an inner marginal extremity head 25 on a radially inwardly extending annular inner marginal flange 27 of an wally inwardly extending side wall portion 28 at the radially inner side of the outer cover member 21 and also dimensioned to extend into the wheel body annular groove.

At the axially outer end of the substantial axial flange side wall 28 it merges into a generally radially outwardly and axially outwardly oblique annular intermediate portion 29 that merges on an axially outwardly extending annular rib 30 with an outer generally radially outwardly and axially inwardly sloping annular marginal portion 31. It will be observed from FIG. 2 that the outer annular cover portions 29 and 31 are dimensioned to substantially overlie the tire rim, with the extremity of the portion 31 lying adjacent to the extremity of the terminal flange 18 and the outer cover member 21 as a whole providing a substantial chamber therebehind within which a valve stem 32 (H6. 1) is readily accommodated in concealed relation.

For supporting the wheel cover entirely upon the tire rim and for retaining the cover on the wheel by engagement with the tire rim, supporting and retaining means are provided behind the cover member 21. For this purpose, the marginal portion 51 is provided with an underturned flange 33 that joins the cover portion 31 on a reinforcing and finishing bead-like juncture 34 and is preferably in nested abutment against the back of the marginal portion 31. Extending generally axially inwardly from the underturned flange 33 is an annular preferably continuous cover supporting and retaining flange 35 of substantial length. This flange is preferably of larger diameter than the diameter described about the axially outer portion of the intermediate flange 17 of the tire rim and is provided with a radially inwardly offset and axially inwardly facing annular shoulder 3'7 that is arranged to seat upon the radially inner portion of the terminal flange l8 adjacent juncture thereof with the intermediate flange 17, for

thereby supporting the cover on the tire rim.

Extending generally axially inwardly from the inner side of the shoulder 37 is a preferably continuous annular flange extension 38 provided with tire rim engaging cover retaining means, in the present instance in the form of a plurality of axially inwardly extending finger extensions 39 provided at their inner extremities with short and sti-l generally radially and axially outwardly oblique retaining terminal flanges that are adapted to grip in cover retaining firm edgewise engagement against the inner surface of the terminal flange There may be as many of the retaining fuigers 39 separated by intermediate preferably arcuate recesses or cutouts 41 as desired, for example eight to sixteen or such fingers. In general, such a retaining finger construction is covered in my Patent No. 2,624,634 issued lanuary 6, 1 953.

in applying the cover to the outer side of the wheel, the retaining fingers 39 are generally centered with relation to the axially outer side of the intermediate fiang 17 of the tire rim and then by means of axially inwar pressure exerted against the wheel cover the retaining finger terminals 46 will cam inwardly from an initially slightly larger diameter described thereabout than the diameter of the inside surface of the intermediate flange axially inwardly along the surface of the intermediate flange and will gradually be radially inwardly resiliently deflected and tensioned for exerting the gripping engagement against the tire rim flange. Axially inward movement of the cover during application to thewheel is limited by engagement of the annular shoulder 37 against the opposing shoulder of the tire rim. As a result, the outer annular cover member '21 is supported especially in the marginal portion'thcreof in substantially spaced relation to the tire rim by the extent of the axial y outer portion of the flange 35, and the cover member 29 is supported in spaced relation to the wheel body by its connected relation to the outer cover member 21 at the axially inse juncture or" the cover members.

It will also be observed that the angular offset structure of the annular shoulder 37 substantially stiiiens the resillent cover retaining flange structure more particularly the relatively narrow finger carrying axially inner flange portion juncture of the shoulder 37 with the flange 35 is on a short ra ius annular rib while juncture of the shoulder 37 with'the flange extensi n Ed is on a short radius annular rib 43. The ribs i2 and 43 aflord a generally corrugated resiliency enhancing reinforcing efiect enhan ed, of course, by the narrow angular structure of theshoulder 37. Therefore, the retaining fingers 39 which are relatively short and allmutually connected through the flange 33 the reinforcing rib structure are on dowed with a substantial degree of resilient stiffness for efficiently gripping the intermediate flange of the tire rim and thus eilecti ely holding the cover on the wheel in service.

Both of the cover members 29 and'Zl are adapted to be made from suitable sheet material such as stainless 4 therein an annular generally axially outwardly extending rib R of generally lJ-shaped cross-section opening axially rearwardly and with the radially inner leg merging into the generally dished radially inner surface of the cover member. The other or outer leg of the rib merges into a preferably initially generally radially outwardly extending flat flange P which is subsequently formed into the cover retaining and supporting flange structure. This stage in the method of making the cover member 21 is depicted in FIG. 4. Then, the flange F is appropriately trimmed and cold worked into axial extension of the outer side wall of the rib, substantially into the form shown in FIG. 5, and the retaining finger terminals it are provided on the retaining fingers 39. Thereafter the rib R is bent laterally and radially outwardly through and beyond the circle of the axial flange F into a position at an angle to the dished inner surface of the cover member, substantially as shown in dash outline in FIG. 6, whereby to increase the overall diameter of the member and with the flange F extending generally axially thereunder and radially inward and forming a portion of the flange structure that provides the cover retaining means. Finally the rib R is worked into the generally radially outwardly and axially inwardly more or less oblique form of the final cover as shown in dash outline in FIG. 7 and in full outline in FIG. 2, but with the flange F carrying the retaining fingers 39 still in an axially inward substantially straight condition. it

will be observed that as the rib R is progressively bent outwardly it is also collapsed so that finally'the outer marginal portion 31 is derived from substantially the radially inner side of the rib and the underturned flange 33 from the radially outer side of the rib.

As the final step in the formation of the cover member 21; the flange F is cold worked to provide the same with the shoulder 37 and the reinforcing and juncture corrugation ribs 42 and 43. This is elfectively accomplished as depicted in FlGS. 8 and 9 and with apparatus as shown in these figures. Accordingly, the cover member 21 with the straight flange F is placed within a dished or recessed upwardly opening rotary die member 5E3 secured to and rotatably supported bya spindle 52% at the center thereof. An upstanding annular wall 51 of the supporting die member has an upper margin 52 that is obliquely/conformed to be complementary tofthe intermediate cover portion 52', but the inside diameter of the upstanding Wall 51 is preferably constructed to be of substantially larger diameter than the outside diameter of the cover Wall flange portion 23 but complementary thereto so that when the cover is eccentrically disposed within the cavity within the die member 56 the cover wall flange 2i; and the intermediate cover flange portion steel or brass'strip and one or both of the members may be made from othersheet metal'such as aiurninum'alloy of appropriate cold work hardenabihty and finish capability. The cover members are preferably made by stamping or drawing to shape with appropriate cold working of portions thereof to which resiliency must be imparted.

An especial problem is encountered in providing the outer cover member 21 with the supporting and retaining flange and finger structure. For the most part, such flange and finger struc ure may be made according to the meth- 0d disclosed in my Patent 2,707,449 issued May 3, 1955.

To this end, the'steps depicted inFlGS. 4 through 7 may be-followed. Accordingly, the coyer member 21. is preliminarily drawn in a sheet metal blankwherein substantially the entire outer periphery of the blank is employed to form the periphery of and the retaining means for the cover member. The inner or central portion of the blank is generally dished inwardly to provide the inner extremity flange 27 the a 1y extendirn wall or body flange portion 28; as well the generally radially extending intermediate'annular portion 25.

At its outer margin, the blank is cold worked to form 29 will snugly engage the cavity side wall and upper marginal surfaces. 7

At its outer periphery the die member 5b is preferably I constructed substantially cylindrically but with a radially outwardly or lateral upper marginal overhanging shoulder 53 which is of a radial width equal to the ofiset width of the ultimate cover shoulder 37 and provides an axially inwardly facing shoulder 5d which is the formin surface against which the shoulder 37 is adapted to be formed. Appropriate radius corner and fillet provides surfaces for formation of the corrugation rib junctures 42 and 43. The elevation OI" the overhanging forming rib shoulder 53 is such that when the cover member 21 is disposed within theica ity or" the die memberitl with the'bead'ZS resting in the bottom of the cavity, the outer peripheral cylindrical face of the shoulder 53 will be engageable atthe inner side of the flange F at the'appropriate position for formation of the ofiset shouler 37 by cooperating forming roller assembly means 55.

Herein the roller. assembly means 55 includes a clamping roller 57 anda forming roller 58. These rollers are preferably mounted for relative radial movement toward and away from the'forming die member-5i and also for relative radial movement with respect'to each other. The roller 57 is rotatably and laterally shiftably carried by a shaft 59 while the roller 58 is rotatably and laterally shiftably carried by a suitable shaft 60.

Herein the upper roller 57 is constructed and arranged to function as a combination hold down and cover turning roller. For this purpose the roller 57 comprises an upper hold down collar portion 61 and a lower cylindrical cover flange gripping and turning portion 62, with an annular radially outwardly opening groove 63 between the two portions of the roller receptive of the turned over multilayer marginal flange structure 31, 33 of the cover member while the cylindrical lower roller portion 62 engages the flange F and presses it against the cylindrical periphery of the forming shoulder 53.

It will be observed that the groove 63 is generally conformed in the upper portion thereof to the slanting surface of the uppermarginal flange 31 of the cover, while the lower surface defining the groove, that is the surface on top of the margin of the lower roller portion 62 may be flat to accommodate thereover the cover margin bead 34. Through this arrangement, the upper roller portion 61 overlying the cover margin prevents upward displacement of the cover while the lower roller portion 62 presses the flange F against the forming shoulder 53 and by rotation of the roller 57 causes the cover and thereby the rotary die member 50 to turn for progressive circumferential working upon the flange F. Freedom from strain upon the cover as well as upon the forming rolls is implemented by the transverse or radial clearance afforded within the cavity of the rotary die member 50 so that as the periphery of the roller portion 62 presses the progressive circumferential portions of the flange F against the forming shoulder rib 53, the cover is progressively shifted toward the opposite side of the die cavity and away from the area of roller engagement with the flange.

As the upper hold down and turning roller 57 engages progressive circumferential portions of the flange F, the lower roller 58 operates as shown in FIG. 9 to effect progressive insetting of the lower marginal portion of the flange and the retaining fingers 39. This is accomplished by inward shifting of the roller 58 to press the lower marginal portion of the flange against the outer periphery of the side wall 51 of the die member 50 below the forming rib shoulder 53, and against the underside shoulder surface 54. It will be observed that the edge of the roller 58 that engages at the inner juncture of the rib shoulder 53 with the side wall 51 of the die member is formed on a radius complementary to the radius at such juncture, and that the lower outer corner on the die member shoulder rib 53 is also on a suitable radius so as to effect in the final shape of the flange bent thereby the substantially corrugation reinforcing rib junctures 42 and 43.

After the depending cover supporting and retaining flange is formed about the entire periphery of the cover by the coaction of the forming die member and the forming and hold down rolls, the roll assembly '55 is backed off from the rotary die member 50 and the completed cover member 21 removed from the die member 59. The cycle of operation is then repeated with another partially formed cover member 21.

It will be appreciated that as a result of the cold working to which the flange F is subjected during the forming steps as depicted in FIGS. 4 through 7, and then the additional cold working to which the flange is subjected by the formation of the offsetting shoulder 37 therein, substantial resilient stiffness is imparted to the completed flange and the retaining fingers 39. This is highly desirable for affording a highly efficient cover retaining gripping action of the retaining fingers 39 in association with the tire rim flange.

It will be understood that modifications and variations may be eflected without departing from the scope of the novel concepts of the present invention.

I claim as my invention:

1. In a method of making wheel covers, shaping a sheet metal blank into a circular member body with a return bent outer generally radially projecting marginal formation and a retaining flange extending axially therefrom in concealed relation spaced radiallyinwardly from the edge of said marginal formation, supporting said marginal formation against axial displacement, and while thus supporting said marginal formation bending said axially extending flange intermediate its length into a generally radially inwardly extending oflsetting reinforcing and seating shoulder .but maintaining the flange on opposite axial sides of the shoulder in the axial orientation but with the free end portion of the flange offset radially inwardly relative to the axial portion of the flange between said shoulder and said marginal formation.

2. In a method of making a sheet metal blank a circular wheel cover or trim member, shaping the blank into a circular body having a generally radially outwardly projecting annular return bent marginal formation with an axially extending flange of substantial length projecting from said marginal formation and spaced substantially radially inwardly from the edge of the marginal formation, holding said marginal formation against axial displacement, while thus holding said marginal formation intermediately bending said axially extending flange by rolling the same between forming rolls into radially offset axially extending portions with the free end portion of the flange offset radially inwardly from and connected by an axially facing otfsetting shoulder to an axially extending portion of the flange joined to said marginal formation.

3. In a method of making a circular wheel cover ortrim member from a sheet metal blank, shaping the blank into a circular body with an annular radially outwardly projecting return bent marginal formation and an axially extending retaining flange projecting from the return bent marginal formation and spaced substantially radially inwardly from the edge of the formation, shaping the free extremity portion of said flange into retaining means, holding said marginal formation against axial displacement, and while thus holding the marginal formation intermediately bending said flange and thereby moving the free end portion thereof inclusive of said retaining means radially inwardly relative to that portion of the flange which joins the marginal formation and providing an offsetting axially facing shoulder between said portions of the flange adapted to seat on a portion of a wheel to which the member may be applied and whereupon said portion of the flange joined to the marginal formation will serve as a spacer for the marginal formation relative to the wheel.

References Cited in the file of this patent UNITED STATES PATENTS 843,518 Clarke Feb. 5, 1907 1,671,994 Nelson June 5, 1928 1,828,464 Harrison Oct. 20, 1931 2,239,368 Lyon Apr. 22, 1941 2,357,793 Clark Sept. 12, 1944 2,368,228 Lyon Jan. 30, 1945 2,567,334 Harrison et al. Sept. 11, 1951 2,597,010 Lyon May 20, 1952 2,689,595 Belada Sept. 21, 1954 2,707,449 Lyon May 3, 1955 2,725,257 Maurer et al. Nov. 29, 1955 2,740,451 Knost Apr. 3, 1956 

